Abstract: One aspect of a process of forming an aircraft component includes bonding a first end of a honeycomb structure to a surface of an aircraft skin member, the honeycomb structure including multiple connected cells. Foam is sprayed on a second end of the honeycomb structure opposite the first end. The process also includes curing the foam on the second end of the honeycomb structure.

Abstract: A method of manufacturing a composite core can include: wrapping a mandrel in a mandrel wrapping process by securing a mandrel with a winding jig; orienting the composite material at a wrap angle to the mandrel; and depositing the composite material around a circumference of the mandrel. The method can further include assembling the wrapped mandrels in a tool and applying a pressure to the composite material during a curing cycle.

Abstract: A method of assembling a core stiffened structure that includes bonding a composite core to a substructure by utilizing magnetic force to create pressure between a flat surface of the composite core the substructure, and bonding a face sheet onto a surface network of the composite core.

Abstract: A method of manufacturing a composite core can include: wrapping a mandrel in a mandrel wrapping process by securing a mandrel with a winding jig; orienting the composite material at a wrap angle to the mandrel; and depositing the composite material around a circumference of the mandrel. The method can further include assembling the wrapped mandrels in a tool and applying a pressure to the composite material during a curing cycle.

Abstract: A method of making a composite core can include configuring a plurality of mandrels to have a desired thermal expansion characteristic, placing a composite material around each mandrel, placing the plurality of mandrels in a tool, the tool being configured to constrain the plurality of mandrels as the mandrels experience a thermal expansion, heating the mandrels so that the mandrels thermally expand, thereby applying a pressure to the composite material during a cure cycle, and then cooling and separating the mandrels from the composite core. The mandrel is configured as an internal form for making a tube member of a composite core.

Abstract: A method of wrapping a plurality of mandrels with a composite material can include rotating each mandrel at a rotational speed; translating each mandrel at a translation speed; positioning each mandrel back to back such that an aft face of a preceding mandrel is approximate to a forward face of a trailing mandrel; and sequentially wrapping each mandrel with the composite material in a helical orientation.

Abstract: A method of assembling a core stiffened structure that includes bonding a composite core to a substructure by utilizing magnetic force to create pressure between a flat surface of the composite core the substructure, and bonding a face sheet onto a surface network of the composite core.

Abstract: A structural joint includes a first member having a first base portion and a first leg portion. The structural joint further includes a second member having a second base portion and a second base portion. The first base portion and the second base portion are coupled together at an overlapping portion. The first leg portion and the second leg portion form a cavity for structurally coupling to a structural member.

Abstract: A structural joint includes a first member having a first base portion and a first leg portion. The structural joint further includes a second member having a second base portion and a second base portion. The first base portion and the second base portion are coupled together at an overlapping portion. The first leg portion and the second leg portion form a cavity for structurally coupling to a structural member.

Abstract: A method of manufacturing a core stiffened structure includes orienting the plurality of core wafers in a non-uniform pattern onto a first face sheet, the non-uniform pattern producing non-uniform spacing between adjacent core wafers; assembling a second face sheet onto the plurality of wafers; and curing an adhesive to create a bond between the plurality of wafers, the first face sheet, and the second face sheet.

Abstract: An airfoil member can have a root end, a tip end, a leading edge, and a trailing edge. The airfoil member can include an upper skin, a lower skin, and a composite core member having a plurality of cells, an upper surface network of the cells can be bonded to the upper skin, a lower surface network of the cells can be bonded to the lower skin. The composite core can have a septum layer embedded in the cells that form the composite core, the septum layer being configured to provide tailored characteristics of the airfoil member.

Abstract: A method of wrapping a plurality of mandrels with a composite material can include rotating each mandrel at a rotational speed; translating each mandrel at a translation speed; positioning each mandrel back to back such that an aft face of a preceding mandrel is approximate to a forward face of a trailing mandrel; and sequentially wrapping each mandrel with the composite material in a helical orientation.

Abstract: An apparatus comprising a soft in plane rotor yoke comprising two longitudinal side portions connected together via two outboard portions, wherein the outboard portions comprise a plurality of first layers formed of a first composite fabric material having a plurality of first fibers oriented in a first direction, and a plurality of second layers formed of a second composite fabric material having a plurality of second fibers oriented in a second direction. Included is an apparatus comprising a soft in plane rotor comprising two longitudinal side portions connected together via two outboard portions, wherein the outboard portions comprise a plurality of first layers formed of a first composite fabric material, and a plurality of second layers formed of a second composite fabric material, wherein the soft in plane rotor yoke does not comprise any narrow steered slit tape or filament windings.

Abstract: A method of manufacturing a composite core can include: wrapping a mandrel in a mandrel wrapping process by securing a mandrel with a winding jig; orienting the composite material at a wrap angle to the mandrel; and depositing the composite material around a circumference of the mandrel. The method can further include assembling the wrapped mandrels in a tool and applying a pressure to the composite material during a curing cycle.

Abstract: A method of making a composite core can include configuring a plurality of mandrels to have a desired thermal expansion characteristic, placing a composite material around each mandrel, placing the plurality of mandrels in a tool, the tool being configured to constrain the plurality of mandrels as the mandrels experience a thermal expansion, heating the mandrels so that the mandrels thermally expand, thereby applying a pressure to the composite material during a cure cycle, and then cooling and separating the mandrels from the composite core. The mandrel is configured as an internal form for making a tube member of a composite core.

Abstract: A method of manufacturing a composite core can include: wrapping a mandrel in a mandrel wrapping process by securing a mandrel with a winding jig; orienting the composite material at a wrap angle to the mandrel; and depositing the composite material around a circumference of the mandrel. The method can further include assembling the wrapped mandrels in a tool and applying a pressure to the composite material during a curing cycle.

Abstract: A method of manufacturing a composite core can include: wrapping a mandrel in a mandrel wrapping process by securing a mandrel with a winding jig; orienting the composite material at a wrap angle to the mandrel; and depositing the composite material around a circumference of the mandrel. The method can further include assembling the wrapped mandrels in a tool and applying a pressure to the composite material during a curing cycle.

Abstract: A helicopter rotor blade includes a structural composite skin defining a cavity therein; a composite spar disposed within the cavity and adhesively bonded to the skin, a portion of the spar exhibiting a C-shape in cross section; and a foam core disposed within the cavity and adhesively bonded to the skin. The structural composite skin forms an external, closed box structure configured to transmit mechanical loads encountered by the rotor blade.

Abstract: A method of making a rotor yoke includes preparing a cured composite rotor yoke preform on a single-sided curing tool and machining at least one portion of the cured rotor yoke preform to form a rotor yoke. In one embodiment, preparing the cured composite rotor yoke is accomplished by applying successive layers of uncured polymeric composite material to a single-sided tool in a configuration to produce an uncured rotor yoke preform; disposing a semi-rigid caul to an untooled side of the uncured rotor yoke preform; enclosing the uncured rotor yoke preform and the semi-rigid caul by substantially hermetically sealing a vacuum bag to the tool; substantially evacuating a volume defined by the vacuum bag and the tool of air; and heating the uncured rotor yoke preform, sometimes under pressure, to form the cured composite rotor yoke preform.

Abstract: A structural joint includes a first member having a first base portion and a first leg portion. The structural joint further includes a second member having a second base portion and a second base portion. The first base portion and the second base portion are coupled together at an overlapping portion. The first leg portion and the second leg portion form a cavity for structurally coupling to a structural member.